Advanced Process Modelling and Simulation of Multi-Material Directed Energy Deposition

As technology advances, materials face increasing demands, especially in the aerospace industry. Metal additive manufacturing (AM), specifically directed energy deposition (DED), addresses these needs by enabling multi-material deposition and in-situ alloying, producing functionally graded materials (FGMs) with tailored properties by combining different materials. Numerical simulations can be used to predict temperature fields and distortions in the DED process, reducing costly trial runs. However, incorporating FGMs in such thermomechanical simulations of DED process requires development of new process models and creation of material models for specific alloy combinations. Using Simufact Welding and extending the capabilities of the software, a DED process is modelled, and material compositions are assigned to layers to construct FGMs virtually in this work. Initial process simulations of CuCrZr-IN718 FGM deposition on a CuCrZr substrate demonstrate successful modelling of the process. These models correlate well with experimental results, predicting temperature fields and distortions effectively. Future work includes further validation and scaling simulations for industrial applications.     «

As technology advances, materials face increasing demands, especially in the aerospace industry. Metal additive manufacturing (AM), specifically directed energy deposition (DED), addresses these needs by enabling multi-material deposition and in-situ alloying, producing functionally graded materials (FGMs) with tailored properties by combining different materials. Numerical simulations can be used to predict temperature fields and distortions in the DED process, reducing costly trial runs. Howev...     »